Formwork and Falsework

Falsework means the temporary structure used to support a permanent structure, material, plant, equipment and people until the construction of the permanent structure has advanced to the stage where it is self supporting.

Falsework includes the foundations, footings and all structural members supporting the permanent structural elements. Falsework can be used to support formwork for in-situ concrete, prefabricated concrete elements, steel sections or stone arches e.g. during bridge construction. The major risks related to formwork include falls from platform edges or through penetrations, being hit by falling timbers or crane loads, formwork collapse and contact with powerlines.

‘Formwork’ for the purpose of this HRS includes conventional and engineered formwork systems used for the structural support of concrete for suspended slabs, penetration in-fills, columns and walls including:

The risks arising from formwork and/or falsework are to be identified, assessed, and controlled in the Project Risk Register, in accordance with the hierarchy of controls.

A structural or geotechnical engineer shall conduct an assessment and provide to designer

A design MUST be provided for all Formwork Systems, designed by a qualified engineer in accordance with the requirements set out in AS 3610 – Formwork for Concrete and AS 3600 – Concrete Structures.

All contractors must identify any High Risk activity within their scope of work, evidence of experience carrying out this activity, provision for full time supervision, relevant licenses and competencies of supervisor and workers to erect/dismantle formwork and/or falsework

All contractors are required to develop and submit, a specific safe system of work, e.g. SWMS, for formwork and/or falsework to the Baseline site representative for approval (7days) prior to commencing works

This MUST include an Emergency Procedure / Rescue Plan, evidence that supervisors and workers are trained in the procedure

Note: The Baseline expectation is that our contractors will follow all safety requirements listed within our standards

Proposed methodology to be reviewed by Project Team and assess for need to conduct activity specific High Risk Workshop.

Formwork design MUST be reviewed and approved by Baseline project/site manager

(If required) High Risk Workshop to be conducted with contractor undertaking activity and Baseline Project Team.

Methodology, competencies and timing MUST be confirmed and agreed with all stakeholders

Formwork contractors safe systems of work and SWMS, addressing the installation, monitoring and dismantling of the formwork / falsework system, and competencies of supervisors and workers are required to be reviewed and approved by Baseline site manager to approve the work to proceed.

Note: Work at Heights Permit is required where temporary edge protection cannot be achieved

Baseline site manager / supervisor MUST monitor the formwork installation to ensure it is systematically erected and dismantled by a competent person in accordance with the designer’s or manufacturer’s instructions.

If diagonal bracing or other edge protection is installed progressively on formwork frames, other fall prevention control measures may not be necessary

A Task Observation should be conducted by a Baseline Project Team member to record the works being carried out as per approved SWMS.

The Subcontractor Supervisor MUST be present at all times to ensure the workers are complicit with their SWMS and design installation

At the end of the activity the formwork subcontractor MUST provide an inspection certification/sign off from the Structural Engineer to confirm the formwork has been installed as per the approved design and the formwork deck is safe to access and further works can commence.

A Structural Engineer is required to conduct an inspection and sign off prior to the commencement of concrete pouring, where required.

Where possible, fabricate structures on the ground to eliminate workers being exposed to working at heights risks.

Use alternative construction methods that does not require the use of formwork or falsework, such as pre-cast panels.

Formwork / falsework components must be destroyed if damaged.

Where possible, use remote monitoring methods such as CCTV or remote mounted cameras to monitor loading activities.

Using precast columns and beams instead of constructing formwork and pouring concrete on site.

Where practicable, use proprietary modular formwork systems.

Use mechanical aids like cranes, hoists, pallet jacks or trolleys to move equipment and materials wherever possible instead of manually lifting.

Exclusion zones must be established around formwork and falsework including during erection, loading, pouring and dismantling, with preference given to hard barriers.

Formwork and falsework adjacent to mobile plant operating areas or traffic corridors shall be protected by physical barriers, such as concrete barriers, fences or water filled barriers.

Formwork systems are to be designed and certified in accordance with the requirements set out in AS 3610 – Formwork for Concrete and AS 3600 – Concrete Structures. Falsework must be designed to carry all loads that may be applied during the various stages of its use including dead, live, environmental and other loads

Prior to formwork or falsework work commencing, subcontractors are to provide an Engineers Inspection Test Plan (ITP) and discrepancies rectified

The subcontractors SWMS should indicate the general and any additonal PPE required, which may include hard hats, safety glasses, gloves, harnesses or other in addition to site mandatory PPE.